Dry wall construction and method of assembly



Jan. 9, 1968 H T. WARREN 3,362,120

DRY WALL CONSTRUCTION AND METHOD OF ASSEMBLY Filed OC'h. 18, 1965 2 Sheets-Sheer l BVW DRY WALL CONSTRUCTION AND METHOD OF ASSEMBLY H. T. WARREN Jan. 9, 1968 2 Sheets-Sheet 2 Filed Oct.

2 EM e w 2 M W H 5 rQTTOP/VEV United States Patent 3,362,120 DRY WALL CONSTRUCTION AND METHOD OF ASSEMBLY Hugh T. Warren, Gilman, Iowa, assignor to Holland Plastics Company, Gilman, Iowa, a corporation of Iowa Filed Oct. 18, 1965, Ser. No. 496,869 8 Claims. (Cl. 52309) This invention relates to a wall construction and, in particular, to a dry wall structure having thermal insulation and sound-deadening characteristics and adapted for application to walls formed of cement blocks, poured concrete, and the like, and to the method for constructing such a dry wall structure.

A primary object of this invention is to provide a dry wall structure of a high structural strength having sounddeadening, thermal insulation, and moisture resistant characteristics.

Another object of this invention is to provide a dry wall structure which is economical in cost, easy to install, and of a light weight that does not impair its structural strength or thermal insulation and moisture resistant characteristics.

Another object of this invention is to provide a dry wall construction for a concrete wall in which a panel of a polystyrene material is applied to the wall between furring or anchor members having polystyrene wall contacting members, and wherein gypsum slabs secured directly to the furring members are arranged in a covering relation with the panels and furring members.

Still a further object of this invention is to provide an improved method for applying a dry wall structure to a cement block or poured concrete wall.

Other objects and advantages of the invention will become apparent from the following detailed description taken in connection with the accompanying drawing in which:

, FIG. 1 is a perspective fragmentary view of a concrete block wall structure with the composite dry wall structure of this invention applied thereto, and with parts being broken away, and other parts shown in section for the purpose of clarity;

FIG. 2 is an enlarged sectional view taken along the line 22 of FIG. 1;

FIG. 3 is a reduced rear elevational view of a polystyrene slab which forms part of the dry wall structure;

FIG. 4 is a reduced rear perspective view of a furring strip of the dry wall structure; and

FIG. 5 is a front elevational view of the masonry wall and dry wall assembly with a portion of the finishing panels broken away and the adhesive securing patterns for the foam slabs and finishing panels shown in dotted lines.

Referring to the drawing, there is shown in FIG. 1 a masonry wall 5 of concrete block type with the dry wall structure or assembly of this invention applied thereto and indicated generally at 6. The dry wall assembly 6 includes furring strips 7, polystyrene slabs 8, and covering panels 9. Each furring strip 7 (FIG. 2) includes an outer member 10 formed of a plywood material and an inner member 11 formed of a polystyrene material. The members 10 and 11 are secured together in a back-toback relation by an adhesive material indicated at 12.

The polystyrene members 11 and the slabs 8 are of a commercially available material characterized as a multicellular foam produced by expanding polystyrene beads or crystals approximately forty times. This foam material has excellent characteristics for a dry wall structure such as good sound-deadening properties, low cost, ease of cutting and shaping to a desirable size, light in weight for 3 ,362,126 Patented Jan. 9, 1968 easy handling, low thermal conductivity, and high resistance to the transfer of moisture.

As best appears in FIG. 2, the laminated construction of a furring strip 7 has a composite thickness equal to the thickness of a slab 8. Each finishing or covering panel 9 is of a rectangular shape and preferably formed from a gypsum board material. However, it is obvious that the panel or sheeting 9 could be of a plywood material or of a decorative wood veneer.

In the application of the dry wall structure 6 to the masonry wall 5 it is preferred that the interior surface 13 of the masonry wall be clean, dry, and with all loose particles removed. Poured concrete walls must be dry and free of form coatings, latents and any foreign material. A one-quarter inch bead of adhesive 14 (FIG. 4) is then applied on the foam or polystyrene member 11 of a furring strip 7, along its center line 24 and over the full length of the strip. It is recommended that the adhesive 14 be of a fortified rubber cement type such as Fullers Black Stuff manufactured by H. B, Fuller Company of St. Paul, Minn. Other adhesives may be used that conform to the GDCI (Gypsum Dry Wall Contractors International) specifications for gypsum wall board erection.

The adhesive 14 is allowed about five minutes to become tacky and to permit the dissipation of solvent therefrom. With the adhesive in a state of tackiness, the furring strip 7 is pressed firmly into position against the masonry wall 5. It has been found that best adhesion between the foam member 11 and the masonry wall surface 13 takes place when the surfaces to be adhered are at a temperature of about 50 F. or more.

The furring strips 7 are, additionally, mechanically secured to the wall 5 by concrete nails 16 (FIG. 2), such as Wheeling LaBelle cut masonry nails. The nails 16 are driven into the mortar joints of the wall 5 adjacent to the top and bottom of the wall, with two or more nails being spaced there between. If the masonry joints are exceptionally hard, pilot holes should be drilled to accept the nails 16. The nails 16 are set along the center line 24 and driven into the wall 5 to a depth providing for their heads 15 being set slightly below the exterior surface of the plywood member 10.

A foam slab 8 is then adhesively secured to the masonry wall 5. As shown in FIG. 3, a one-quarter inch bead of adhesive is applied to the rear side 18 of a slab 8 in a pattern consisting of a marginal border 19 of a rectangular shape, a pair of intersecting diagonal adhesive beads 21 within the border bead 19 and rows of adhesive beads 22 arranged within each of the four triangles formed by the intersecting diagonal beads 21. After the adhesive beads 19, 21, and 22 have been allowed about five minutes to become tacky, the rear side 18 of a slab 8 is pressed firmly against the masonry wall 5 between a pair of adjacent furring strips 7 as shown in FIG. 1.

A furring strip 7, as previously mentioned, is of a thickness equal to the thickness of a slab 8. Also, the furring strips 7 are spaced a distance apart equal to the width of a slab 8 so that the sides of a slab are in abutting engagement with corresponding adjacent sides of a pair of furring strips 7. As a result, the exterior surfaces of the furring strips 7 and slabs 8 lie in a common plane and form a single continuous surface as shown in FIG. 2. It is also seen that the slabs 8 and foam members 11 form a continuous polystyrene foam thremal blanket which covers completely the exterior surface of the masonry wall 5.

The dry wall structure 6 is completed by aflixing the wallboard panels 9 to the polystyrene slabs 8 and furring strips 7. A one-quarter inch adhesive bead 20 (FIGS. 2

and is applied the full length along the transverse center line 24 of a furring strip 7, with care being exercised to cover the heads 15 of the nails 16. A one-quarter inch adhesive bead pattern is then applied to the back side 23 of a panel 9, as shown in dotted lines in FIG. 5 in all respects similar to the application of the adhesive bead pattern to a slab 8 as was fully described in connection with FIG. 3.

With the vertical sides of a panel 9 positioned along the center lines 24 of a pair of adjacent furring strips 7, the rear side 23 of the panel is pressed firmly against an adjacent pair of furring strips 7 and the exterior surface of the slab 8 located therebetween. One inch self-tapping Phillips head dry wall screws 26 (FIGS. 2 and 5) are then secured along each vertical side of a panel 9 adjacent to the top and bottom of the panel with a pair of screws evenly spaced between the top and bottom screws. As clearly appears in FIG. 2, the screws 26 are extended through the plywood members 10 of the furring strip 7 and may extend partially within the polystyrene members 11. Adjacent wallboard panels 9 form a continuous vertical exterior surface which is then taped and finished in accordance with proper industry practices.

It is seen, therefore, that the polystyrene members 11 and the slabs 8 form a continuous thermal blanket against the masonry wall 5 and with only the nails 16 being extended into the wall 5. Thermal conductivity is thus limited only to the nails 16 and any transfer of moisture from the wall 5 and through the nails 16 to the panels 9 is substantially eliminated by the adhesive beads 14 and 20, since the nails 16 are extended through the bead 14 and have their inset heads covered by the bead 2d.

The thickness of the polystyrene thermal blanket, comprised of the members 11 and slabs 8, may be varied as desired by maintaining a fixed thickness of the plywood member 10 of a furring strip 7, and then applying thereto a polystyrene member 11 of a thickness which provides an overall thickness dimension to the furring strip that is equal to a thickness of a polystyrene slab 8.

In one embodiment of the invention for a masonry wall 5 providing for an eight foot ceiling, the furring strips 7 are eight feet long and two inches wide. In this furring strip the plywood member 10 is three-eighths of an inch thick and the polystyrene member 11 is five-eighths or" an inch thick. The furring strips 7 are mounted vertically against the masonry wall 5 with their center lines 24 on four foot centers. A slab 8 of a one inch thickness is then cut with a height of eight feet and width of forty-six inches so as to butt fit the floor and ceiling and the vertical sides of adjacent pairs of furring strips 7. The wallboard panels 9 may be eight or twelve feet long, and four feet high, and are arranged horizontally with their vertical edges on the center lines 24 of the furring strips 7. A wallboard panel 5 is illustrated in FIGS. 1 and 5 as being of a twelve foot length.

In the application of the adhesive beads, excessive amounts of the adhesive material may result in the forming of irregularities on the wall surfaces being glued together. Additionally, if more than a one-quarter inch bead of adhesive is used, solvents in the adhesive may become trapped in the wall structure and cause a collapse in the polystyrene foam material.

Although the invention has been described with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited since changes can be made therein which are within the full intended scope of this invention as defined by the appended claims.

I claim:

1. A dry wall structure for a masonry wall comprising:

(a) a layer of thermal insulating material having one side adhesively secured to one side of the masonry wall,

(b) a layer of panel members adhesively secured to the other side of said thermal insulating material layer in a covering relation therewith,

(c) masonry nail means securing spaced portions of said thermal insulating material layer to the masonry wall, and

(d) mechanical means securing adjacent edges of said panel members to said spaced portions of the thermal insulating material.

2. A dry wall structure according to claim 1, in which:

(a) said thermal insulating material layer is composed of a polystyrene foam material.

3. A dry wall structure for a masonry wall, compris- (a) a plurality of vertically elongated horizontally spaced furring strips having a thermal insulating and moisture resistant member adhesively secured to a base member,

(b) means for adhesively securing said furring strips to the masonry wall with the thermal insulating member against said masonry wall,

(0) a thermal insulating and moisture resistant slab member extended between and contacting facing vertical edges of adjacent pairs of furring strips, with one side of said slab members in contact with and adhesively secured to said masonry wall,

(d) a plurality of exterior panel members having adjacent contacting edges positioned longitudinally and centrally of said furring strips, and

(e) means for anchoring said base members to said exterior panel members.

4. A dry wall structure according to claim 3, in which:

(a) said thermal insulating member and said thermal insulating slab member are of a polystyrene foam material.

5. A dry wall structure for a masonry wall structure,

comprising:

(a) a plurality of upright horizontally spaced furring strips secured to the wall structure, each furring strip including a base member and a polystyrene foam member adhesively secured together in a back to back relation, and the foam member being in contact with a side surface of the wall structure,

(b) a polystyrene foam slab member extended between facing edges of adjacent pairs of said furring strips and adhesively secured to said one side surface of the wall structure, said furring strips and a slab member being of equal thickness so that the exterior surfaces thereof lie in a continuous common vertical plane, and

(c) sheeting members arranged in a covering relation with said exterior surfaces and secured to the base members of said furring strips.

6. A dry wall structure for a masonry wall compris- (a) a plurality of vertically extended horizontally spaced furring strips secured to one side surface of said masonry wall, each furring strip being of a laminated construction with the laminations adhesively secured together and including an inner polystyrene foam lamination and an outer base lamination,

(b) a plurality of anchor members for securing a furring strip to said masonry wall with the inner polystyrene lamination against said one side surface of the masonry wall, said anchor members extended through a furring strip and into said masonry Wall,

(c) a polystyrene foam slab member adhesively secured to the one side surface of said masonry wall of a shape and size to cover the area of the exterior surface of the masonry wall located between said furring strips, said slab member having a thickness equal to the thickness of a furring strip so that the exterior surfaces of said base members and slab members lie in a common plane,

(d) panel members arranged in a covering relation with said furring strips and slab members, each panel member having the vertical side portions thereof in an overlapping relation with certain pairs of said furring strips, and

(e) securing means extended through said vertical side portions and into the base laminations of said certain furring strips.

7. A dry wall structure according to claim 6 wherein:

(a) said anchor members have the exterior ends thereof inset within a corresponding outer base lamination,

(b) beads of a rubber cement material applied in a covering relation over the exterior ends of said anchor members, and

(c) other beads of a rubber cement material applied to the interior surfaces of said polystyrene laminations at positions to be penetrated by said anchor members.

8. A method of constructing a dry wall structure for a masonry wall comprising the following steps:

(a) providing a plurality of furring strips each of which is of a laminated construction having a wall contacting water resistant and thermal insulating lamination and an exterior base lamination,

(b) mechanically securing said furring strips to said masonry wall in a vertically extended horizontally spaced relation by anchor members inset within said base laminations and anchored within said masonry wall,

(c) cutting water resistant and thermal insulating slab members to a thickness equal to the thickness of the furring strips and to a shape and size to completely cover the area of the wall between adjacent pairs of said furring strips, whereby to form, with said masonry wall contacting laminations, a continuous water resistant and thermal insulating blanket in contact engagement with said masonry wall,

((1) adhesively securing said slab members to said masonry Wall, and

(e) mechanically securing finishing panels to said base laminations in a covering relation with said furring strips and slab members to form a continuous coplanar exterior surface.

JOHN E. MURTAGH, Primary Examiner. 

6. A DRY WALL STRUCTURE FOR A MASONRY WALL COMPRISING: (A) A PLURALITY OF VERTICALLY EXTENDED HORIZONTALLY SPACED FURRING STRIPS SECURED TO ONE SIDE SURFACE OF SAID MASONRY WALL, EACH FURRING STRIP BEING OF A LAMINATED CONSTRUCTION WITH THE LAMINATIONS ADHESIVELY SECURED TOGETHER AND INCLUDING AN INNER POLYSTYRENE FOAM LAMINATION AND AN OUTER BASE LAMINATION, (B) A PLURALITY OF ANCHOR MEMBERS FOR SECURING A FURRING STRIP TO SAID MASONRY WALL WITH THE INNER POLYSTYRENE LAMINATION AGAINST SAID ONE SIDE SURFACE OF THE MASONRY WALL, SAID ANCHOR MEMBERS EXTENDED THROUGH A FURRING STRIP AND INTO SAID MASONRY WALL, (C) A POLYSTYRENE FOAM SLAB MEMBER ADHESIVELY SECURED TO THE ONE SIDE SURFACE OF SAID MASONRY WALL OF A SHAPE AND SIZE TO COVER THE AREA OF THE EXTERIOR 